Fuzzy c-means clustering based colour image segmentation for tool wear monitoring in micro-milling

• Published in: Precision engineering Vol. 72; pp. 690 - 705
• Main Authors: Malhotra, Jitin, Jha, Sunil
• Format: Journal Article
• Language: English
• Published: Elsevier Inc 01.11.2021
• Subjects: Colour image segmentation; Fuzzy c-means clustering; Image registration; Micro-milling; Tool wear; Image registration; Micro-milling; Colour image segmentation; Fuzzy c-means clustering; Tool wear
• ISSN: 0141-6359; 1873-2372
• DOI: 10.1016/j.precisioneng.2021.07.013

Micro-milling is an extensively used micro-machining process for producing high precision 3D components from varied materials. However, tool wear in micro-tools is a big concern, as component accuracy directly depends on it. Also, size effects limit the monitoring by the naked eye, but it can be compensated by implying a proper wear monitoring mechanism. Various direct and indirect methods have earlier been used for monitoring purposes, and considering the needs of the fourth industrial revolution, one of the direct methods, machine vision, when combined with image processing algorithms, can play a more prominent role. Current work focuses on creating a wear monitoring algorithm based on fuzzy c-means clustering technique directly implied on acquired colour micro-tool images. The proposed algorithm has three steps: the first step is Region of Interest (ROI) extraction, where the background is removed, orientation correction is done, and ROI on each tooth is extracted from micro-tool colour images. The second uses the fuzzy c-means technique on ROI to cluster them, from which wear cluster is chosen and morphologically enhanced. The last step performs pixel level measurement and results in numerical wear width. Overall, quantitative results at each step are correlation coefficient of 99 % after image registration, segmentation accuracy of 92 % and wear measurement accuracy of 97 %. A comparison is also made between the proposed algorithm, k-means clustering and RGB thresholding technique, where the proposed algorithm outshines. Lastly, the wear measurement error of the proposed algorithm is less than 5 %, indicating its repeatable, reliable, and robust nature. •A three-step micro-tool wear monitoring algorithm is proposed for wear segmentation and quantification from colour images.•Intensity-based image registration and FCM clustering are used for tool wear segmentation.•Three steps of the algorithm are ROI extraction, wear segmentation, and wear measurement.•Overall, wear measurement accuracy is found to be 97% for the proposed algorithm.